Adjustable composite form



Aug. 29, 1967 E M YOUNG Y 3,338,058

ADJUSTABLE COMPOSITE FORM Filed July 27; 1964 INVENTOR Y EDWARD M. YOUNG ATTORNEY.

United States Patent 3,338,058 ADJUSTABLE COlVIPOSITE FORM Edward M. Young, 90 Gregory Ave.,

West Orange, NJ. 07052 Filed July 27, 1964, Ser. No. 385,138 6 Claims. (Cl. 6154) This invention relates to improvements in piling and particularly relates to improved methods and means for rehabilitating defective piles made of wood, metal, concrete or combinations thereof.

Structural piles are used to support or form the foundations for structures, such as buildings, bridges, piers, wharves, tanks, conduits, etc., by inserting them into or through the yielding surface stratum or floor far enough to obtain support for the principle structure which is to repose thereon.

As is well known, piles are frequently subject to deterioration when exposed to salt or brackish water or chemically polluted water or when exposed to changing tides and/ or water tables. This is particularly true of untreated wood piles or of old treated piles, the treatment of which has lost its effectiveness through age or exposure. in free water, these piles are subject to rot mainly between the high and low water mark, and both are attacked by marine bores, toredo, limnoria and other marine life. Furthermore, these piles are highly vulnerable to damage by fire, particularly when used for the support of piers, wharves, tressles and etc., where some part of the pile extends above water. Under similar conditions, both concrete and steel piles, while not subject to attack from marine bores, etc., and while less susceptible to fire are, nonetheless, subject to corrosion (also mainly between the high and low water marks) and are subject to damage and breakage as the result of high impacts such as might result from the improper handling or berthing of a ship.

Under present practice, marine structures supported by damaged or deteriorated piles are rehabilitated in a variety of ways, some of which require temporary abandonment of the facility until substantial completion of repairs, said repairs being expensive, time-consuming and often disruptive to the normal utilization of the facility even when kept in operation. It is not uncommon under these conditions for an owner to demolish and replace, totally or in part, an existing structure supported by a large number of damaged or deteriorated piles rather than attempt repairs, even though the unsatisfactory part of each pile may well be but a fraction of its total length, with the sound and usable part of each pile making up the greater portion of its total length.

The damage or deterioration sustained by the structural piling occurs between the high and low water marks. It is therefore essential that repairs be carried as low as possible. Ideally, this would involve repairs even below the low water line but, since normal subaqueous operatives require the use of the expensive and necessarily slowworking divers, it is neither practical nor economically feasible to carry on such repairs on a great scale. If repairs are carried on to the low water mark, several problems both structural and economic-are present. In the case of piles badly damaged close to the low water mark, any connection made between a new extension member and the sound portion of the existing pile is of necessity short, this sound portion existing from the water level to the start of the deteriorated portion of the pile. This connection, because of the small bonding area, produces only a limited strength and is often of questionable soundness. Even if such connection to the low water level were satisfactory, there remains the question of slow and uneconomical work, particularly in tidal waters where the 3,338,058 Patented Aug. 29, 1967 ICC.

need to make installations at the low water line often limits to a few minutes each day the working period for making such connections.

The deleterious effects of this short working period are compounded by the need for cutting and fitting each and every connection to the size and shape of individual piles. This is particularly true of wood piles which often vary greatly in size and shape, having neither a constant crosssectional area nor a uniformly round shape. It is also often true of steel or concrete piles which have been damaged or deteriorated, to the extent that their crosssectional shape and size has been altered.

The above limitations and shortcomings are obviated by the invention described herein which has for its purpose the speedy and economical rehabilitation of damaged or deteriorated wood piles, or the extension of sound wood piles by facilitating the placement around and above such piles an adjustable form or mold capable of taking on the cross-sectional shape of said pile to permit the erection of a cast-in-place concrete shaft representing the replacement of the removed damaged portion of the pile.

It is therefore a principal part of the invention to provide improved methods and apparatus for the rehabilpiles without abandoning, suspending or removing the structural facility supported by the piling and thus assuring the continuity of its operation.

A still further object of the invention is to provide methods and apparaus for rehabilitating damaged piles which permit operation thereon at and below the water line without the use of divers and further permits deep water operation with divers in very short periodsof time, and

A still further object of the invention is to provide composite pile forms which are conveniently, easily and accurately fitted and adjusted to and aligned with damaged piles to permit the rehabilitation thereof.

Further objects and advantages will become apparent from a reading of the specifications and a stuty of the accompanying drawings and wherein;

FIGURE 1 shows an elevational view of a rehabilitated pile and form in section according to the invention.

FIGURE 2 shows a longitudinal elevation of a pile por tion and the composite pile form forming a part thereof according to the invention.

FIGURE 3 is a longitudinal sectional view of the pile and form shown in FIGURE 2 according to the invention.

FIGURE 4 is a cross-sectional view of the pile and form through the line 44 of FIGURE 3 showing in part a pyramidal centering and holding device according to one embodiment of the invention.

FIGURE 5 is a crosssectional view of the pile and form through the line 55 of FIGURE 3 showing in particular the over-lapping, inwardly projecting, longitudinally slitted portion of the composite form.

FIGURE 6 is a cross-sectional view of the pile and form through the line 6-6 of FIGURE 3 showing in particular a strapping arrangement for securing the lower portion of the composite form to the pile.

FIGURE 7 is a coss-sectional View of the pile through the line 7-7 of FIGURE 3 showing in particular the slitted portions, each having protrusions extending substantially 90 degrees outwardly therefrom to support a band or strap as shown in FIGURE 6 when securing the composite form to the pile.

FIGURE 8 is a partially sectionalized longitudinal elevational view of the composite form and pile according to another embodiment of the invention.

FIGURE 9 is a cross-sectional view of the composite form through the line 99 of FIGURE 8 showing in particular cross-members diametrically arranged on the form for resting on the top portion of lower pile member thereby setting the form position relative to the pile.

FIGURE 10 is a cross-sectional view of the composite form and pile through the line 1010 of FIGURE 8 showing in particular a guide ring for guiding and positioning the composite form about the pile member.

FIGURE 11 is a cross-sectional view of the composite form and pile through the line 1111 of FIGURE 8 showing in particular a strapping arrangement for securing the lower portion of the composite form to the pile according to another embodiment of the invention.

Now referring to the respective figures where those elements having like function and features will be designated by the same reference numbers, there is shown particularly in FIGURE 1 an elevational view of a rehabilitated pile 1 comprising a pile 2 composed of a lower section 3 and upper section 4, the area between 5 having been removed because of its defectiveness. A composite pile form 6 is substituted for and placed in the area 5 so as to rehabilitate the pile and to permit its continuance as a useful support element. In particular the composite form is made to properly adhere and adjust to the pile sections, to be described later, and concrete poured into the form so that when set a continuous and useful support pile results. In cases where the upper section 4 is rather elon' gated the upper section may remain, however, where this is not so, then the form 6 as shown will extend up to the stringers of the pile cap.

In FIGURES 2 and 3 there is shown partially a composite pile form comprising an elongated cylindrical tube 7, preferably of heavy gauge sheet metal, such as steel, aluminum and etc., but plastic materials are also suitable, open at both extremities, the lower section terminating in or forming an inverted frustum of a cone 8. The cone frustum 8 which forms a continuation of the main body cylinder is generally formed by taking the main cylinder and slitting the lower portion thereof in a longitudinal direction, a number of these slits 9 being equally spaced about the periphery of the cylinder to form a plurality of strips 10. The strips 10 are each bent inwardly in a radial direction about the cone base 11 and each successive strip made to partially overlap, the overlap areas of the strips being progressively greater the closer the approach to the cone apex 13. The flexibility of the strips, each attached to the main body cylinder, is inherent by the nature of the slits and pre-forming thereof radially inward, so that the free ends of the strip members 10 because of such flexibility can be easily manipulated and adjusted about a pile of any form, size and shape. The strips are each free to slide over each other when making any adjustment or fit about a pile, the overlapping areas being greater or smaller depending upon the diameter of the pile about which the cone apex must adjust to.

Each of the strip members 10 have their free extremities 14 bent radially outward on a line that is substantially forty-five degrees from the longitudinal axis of the strip and to such an extent that the top edge 15 of the resulting protrusion 16 is at a sharp angle from the longitudinal axis of the cylinder, thereby providing a protruding lip 17. The combination of such lips in the aggregate forms a washer-like ring about the cone apex useful for supporting any strap or cable lock member 18 to be described.

In a particular embodiment of the invention as shown in FIGURES 3 and 4 there is provided within the composite form or cylinder 7 a form support structure 20 which both centers and positions the form. The structure comprises a pair of inverted V-members 21 and 22 formed of thin reinforcing rods or strapped steel or angle iron set at ninety degrees to each other and spot-welded together at their respective apexes 23 with their bases welded to the cylindrical shell at quarter or degree points 21 on the shell diameter so that the four legs of the inverted Vs form within the shell the form of a foursided pyramid. It is the purpose of these inverted V5 to contact the top edge 25 of the pile 26, as the form 7 is slid over it, and to position the form so that it and the pile are substantially co-axial and concentric. The form and pile are then positioned relative to each other so that the area to be repaired is substantially covered. For cases where the specified distance between the bottom of the form and the cut-off elevation of the pile varies appreciably from pile to pile or is too great to permit the use of the pyramidal centering device, the centering device may be made of an internally supported ring concentric with the form and disposed to slide over and engage the pile as shown in FIGURES 8, 9 and 10. In particular the form positioning structure comprises a ring-like member 25a, co-axial and concentric with the form 26 and internally attached thereto by quarterly spaced support brackets 27 welded to both the form shell and ring member. The ring diameter is sufficient to accommodate the pile and permit the adjustment of the form relative to the pile. The form 26 has further provided a pair of cross metal pieces 28 diametrically positioned to form a plane transverse to the longitudinal direction of the form and supported thereby thus limiting the extent to which the form may be lowered over the pile in the longitudinal direction.

In fabricating or rehabilitating a defective pile, the complete form member 7, as shown in FIGURE 3, is placed over the defective pile 26, after the said pile has had its defective portion removed. The form 7 is slid down over the pile until the pyramidal structure 20 contacts the upper pile edge 26, as previously described, thereby positioning the form relative to the pile in its final resting place. There is further provided a banding or strapping element 20 which surrounds the lower portion of the composite form in the vicinity of the cone apex and is supported by the protrusions 16 which, as previously stated, in the aggregate forms a washer-like element capable of providing said support. The strapping element, supported by the said protrusions, is sufficiently tensioned to permit the form to slidably engage the pile so as to orient and finally position the form relative to the pile. After the form is finally positioned, then the strapping element is firmly tensioned about the periphery of the cone apex to permit complete closure of the slitted flexible elements 10 to provide between these elements themselves and between the said form and pile a seal capable of sustaining the concrete to be placed thereon. The strapping element 30 can be any of the usual tensioning strap devices which are common in the trade. In particular one such strap is shown in FIGUR-ES 2 and 6 and wherein a series of apertures 31 and risers'32 thereon are made to engage each other to permit the intermittent tensioning and release of the strapping element about the composite form. Another arrangement of tensioning is the use of a cable 33, as shown in FIGURES 8 and 11, and wherein sliding self-locking cable grips 34 may be used for securing the form about the pile. The tensioning elements as shown are merely by way of illustration and convenience, it being understood that any suitable tensioning or banding device and means may be used to fasten the form to the pile in a fixed and immovable position.

Subsequent to the placement and adhering of the form to the pile in the defective area, the form is then filled with concrete to the point where the area removed is completely replaced with the said concrete. As shown in FIGURES 2 and 3, if an extension 35 is required it is merely fitted to the upper portion of the form 36 so as to become co-extensive therewith and integral thereto thereby completing the form so as to make a single unit. Also reinforcing steel rods may be placed internally of the form prior to the pouring of concrete to permit a more rigid support member if desired.

Although certain preferred embodiments of the invention have been shown, they are not to be all-encompassing or limiting the extent and scope of the invention. For example, although the composite form has certain flexible elements shown, other flexible means may be used which has for its purpose the matching of the form and any cross-sectional size and shape of piles.

Having defined the invention, what is claimed is:

1. A method for rehabilitating piles having defective areas utilizing a cylindrical pile form having axially slit distensible end members and comprising,

(a) removing the defective areas,

(b) positioning the cylindrical form having axially slit distensible end members over the pile to permit the distensible members to overlap and conform to the pile cross-sectional area,

(c) positioning the form in the defective area about the pile,

(d) fixedly adhering the form at the slit distensible end about the pile, and

(e) pouring in concrete into the form to rehabilitate the defective area.

2. A method for rehabilitating piles having defective areas comprising,

(a) removing the defective areas,

(b) positioning a cylindrical form having axially slit co-extensive distensible end members in the form of a plurality of elongated strips over the pile and adjusting the elongated strips to permit them to overlap so as to conform to the pile cross-sectional area,

(c) positioning the form in the defective area about the '(d) fixedly adhering the form at the distensible end about the pile, and

(e) pouring in concrete into the form to rehabilitate the defective area.

3. A method for rehabilitating piles having defective areas comprising,

(a) removing the defective areas,

(b) positioning a cylindrical form having axially slit co-extensive distensible end members in the form of a plurality of elongated overlapping strips over the pile and adjusting the strips so as to conform to the pile cross-sectional area,

(c) positioning the form in the defective area about the pile,

(d) fixedly adhering the form at the elongated strip ends about the pile, and

(e) pouring in concrete into the form to rehabilitate the defective area.

4. A method for rehabilitating piles having defective areas comprising,

(a) removing the defective areas,

(b) positioning a cylindrical form having axially slit co-extensive distensible end members in the form of a plurality of elongated radially bent overlapping strips over the pile and adjusting the strips so as to permit the elongated strips to conform to the pile cross-sectional area,

(c) positioning the form in the defective area about the (d) fixedly adhering the form by stripping at the elongated strip ends about the pile, and

(e) pouring in concrete into the form to rehabilitate the defective area.

5. A method for rehabilitating piles having defective areas comprising,

(a) removing the defective areas,

(b) positioning a cylindrical form having axially slit distensible end members over the pile to permit the distensible members to conform to the pile and adjusting the members so as to overlap cross-sectional area, the said form including therein a structural frame for guiding the placement of the form about the pile,

(c) positioning the form along the guiding frame in the defective area about the pile,

(d) fixedly adhering the form at the distensible end about the pile, and

(e) pouring in concrete into the defective area.

6. A composite form member for rehabilitating piles having defective areas comprising,

(a) a cylindrical shell form having its lower portion form to rehabilitate the axially slitted to form a plurality of elongated distensible strips extending radially inward to form a cone frustrum at one extremity thereof disposed to fit over and conform to the cross-sectional area of said pile, each of the strips partially overlapping and further having at their extremes a portion thereof outwardly bent to form a support ring about the composite member,

(b) internally mounted pyramidal frame means disposed to permit the frame forming members to engage the pile and cause the said composite form to properly and accurately orient and position itself relative to said pile, and

(c) means carried by said distensible means for fixedly adhering the form about the pile to permit the defective area to be rehabilitated.

References Cited UNITED STATES PATENTS 954,973 4/ 1910 Koetitz 6154 2,222,481 11/1940 Ferguson et a1 6153 X 2,308,793 1/ 1943 Upton 61-54 3,103,103 9/ 1963 Liddell 6154 3,134,236 5/1964 Baittinger 6 1-5 3 DAVID J. WILLIAMOWSKY, Primary Examiner. JACOB SHAPIRO, Examiner. 

1. A METHOD FOR REHABILITATING PILES HAVING DEFECTIVE AREAS UTILIZING A CYLINDRICAL PILE FORM HAVING AXIALLY SLIT DISTENSIBLE END MEMBERS AND COMPRISING, (A) REMOVING THE DEFECTIVE AREAS, (B) POSITIONING THE CYLINDRICAL FORM HAVING AXIALLY SLIT DISTENSIBLE END MEMBERS OVER THE PILE TO PERMIT THE DISTENSIBLE MEMBERS TO OVERLAP AND CONFORM TO THE PILE CORSS-SECTIONAL AREA, (C) POSITIONING THE FORM IN THE DEFECTIVE AREA ABOUT THE PILE, (D) FIXEDLY ADHERING THE FORM AT THE SLIT DISTENSIBLE END ABOUT THE PILE, AND (E) POURING IN CONCRETE INTO THE FORM TO REHABILITATE THE DEFECTIVE AREA. 